Additive manufacturing

Selective Laser Melting (Powder Bed Fusion process) is an innovative technology for manufacturing geometrically complex 3D physical objects by application of the powder, layer after layer, and local melting of selected areas of each layer of the powders of various metal alloys with the beam of a high-power ytterbium fiber laser of continuous radiation. As the source of the formed shape, a CAD model of the required product is used.

Advantages of the technology:

Saving of the expendable material
процесс 3D-печати подразумевает многократное повторное использование материала после его предварительного просеивания на вспомогательном оборудовании. Таким образом, достигается минимальное количество отходов, и значительно снижается конечная стоимость изделий
Solving the most complex technological issues
manufacturing of variety parts with complex geometry, with internal cavities and conformal cooling channels, which are often impossible to manufacture with traditional production technologies
Constructional design speed
significantly reducing the research and development cycle due to a possibility to manufacture products without making expensive accessory equipment
Outstanding mechanical properties
owing to high density (up to 99.99%), the mechanical properties of the products created are not inferior to those of similar products obtained with traditional production technologies, and often exceed them
A wide range of utilized materials
the building process of the products in inert atmosphere of the 3D printer chamber allows the use of an unlimited range of metal alloy powders, including aluminum and medical titanium, as a raw material
Topological optimization
a possibility to topologically optimize the shape of the future product still at the stage of prototyping and to considerably reduce its weight

How it works

Preparing for the 3D printing process begins with a 3D modeling of the desired construction object in one of the existing CAD systems. Then, with the help of the CAM system, a .stl file is created, – an industry standard that fully allows you to get a file with a certain set of parameters necessary for effective 3D printing. In digital processing, the build object model is divided into layers, each 20 to 100 microns thick, and the trajectories of laser beam scanning are formed when each layer is exposed.

The layer formation cycle

1
2
3
4
5
6
Metal powder of pellets of correct spherical shape 5 to 45 μm in diameter

as the main raw material, a variety of metals are used, pulverized into powders with pellets of correct spherical shape. The technology can be used with almost all standardized alloys, as well as to compose and develop special materials to solve individual issues

The metal powder supplying bin

before application of each following layer, the movable platform with the metal powder moves up by the height equal or exceeding the required thickness of the layer

The build platform

the platform, on which the product is printed (grown) layer by layer, is made from a material that is the same or similar in its chemical composition as the metal powder used. After the printing process is finished, the ready product is mechanically separated from the platform, and the platform is polished for reusing

Build shaft

when the laser selective melting of the current layer of metal powder is done, the platform is lowered in the build shaft by exactly the specified height of the printed layer. Over the product and the entire area of the bin, a portion of metal powder is applied for the formation of the next printed layer

Ytterbium fiber laser

of high power and continuous radiation with a high-precision optical system that allows you to focus optical energy to a point with a diameter of 45 to 200 microns, with an even distribution of energy throughout the area of the spot formed in the melt zone

High-speed scanning system

for high-speed optical scanning of the build platform (by deflection of the laser beam), a system based on special mirrors is used that can deflect the beam along the X and Y axes. Each mirror is driven by a micro-servomotor with a highly accurate feedback and a system of programmable correction of positioning

The main application of the technology:

  • manufacturing of multifunctional parts for use in different assemblies, mechanisms and units
  • manufacturing of complex structures, including non-separable, changing their geometry in the course of their operation, as well s having in their composition many different elements
  • manufacturing of shaping elements of molds and dies for casting thermoplastics and other light materials
  • manufacturing of technical prototypes (prototyping) for working out the design of products
  • manufacturing of shaping inserts for die casting
  • manufacturing of individual dental and orthopadical prostheses and implants
  • manufacturing of punches and dies

Applications

Additive technologies that just a few decades ago seemed to be a fantasy, today are successfully implemented in all highly technological and strictly regulated industries


3D printers and auxiliary equipment

3D printer Alfa-150D

A compact solution for ambitious and high-precision industrial and research issues

Read more
3D printer Alfa-280

An ideal solution for mass production and prototyping

Read more
Vacuum powder removal units

Devices are intended for collection of unused metal non-reactive powder from the work area of the Alfa-150D and Alfa-280 3D printers

Read more
Automated metal powder sieving units

Devices for sifting, mixing and homogenizing metal powder for reuse

Read more

Applications

Additive technologies that just a few decades ago seemed to be a fantasy, today are successfully implemented in all highly technological and strictly regulated industries


Do you have any questions or need consultation?

Feel free to reach out to us. Our team of professionals is always ready to assist you.